(Haloneocarbyl-substituted)-bis(aliphatic hydrocarbyl)phosphorates with polyurethanes

ABSTRACT

Included are the title phosphorate compounds, and a process to prepare them comprising contacting a carbylphosphorate acid halide with a carbyloxide. For example, (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate can be prepared with 3,3-bis(bromomethyl)oxetane and bis(ethyl)chloridophosphorate. The compounds are useful flame retardants for polyurethanes, especially flexible foams because, for example, substantially non-scorching and non-odoriferous flame-retardant flexible foams can be readily prepared with the compounds. Also included is a method for inducing scorch in polyurethanes, which can be used to generally determine polyurethane formulations which are prone to not scorch in commercial production.

FIELD

The invention concerns organic phosphorous compounds, their preparation and use. The use particularly concerns flame-retarding compositions such as polyurethanes, for example, flexible foams, which are useful structural materials, for example, in insulating and upholstery cushioning. The invention also concerns a procedure for inducing scorch in polyurethanes, which can be generally used to indicate polyurethane components and formulations which are not prone to scorch in production such as commercial production.

BACKGROUND

Albright et al., U.S. Pat. No. 4,083,825 (1978) and Stanaback et al., U.S. Pat. No. 4,046,719 1977) illustrate certain halogen-substituted phosphates useful as flame retardants in polyurethanes. The phosphates of Stanaback et al. can be certain bis(phenyl) halogenated phosphates.

A problem in the art is production of highly marketable polyurethanes, particularly flexible foams and especially as slabstock. Therein, scorch, odor, processability and flame-retardant efficiency are among production characteristics often needing improvement.

SUMMARY

The invention, in one aspect, is a (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate. Another aspect is a process to prepare said phosphorate comprising contacting a carbylphosphorate acid halide with a carbyloxide under conditions whereby said phosphorate is prepared. Still another aspect is a use of said phosphorate in a method for satisfying a production characteristic of a flame-retardant polyurethane comprising incorporating said phosphorate into polyurethane under conditions whereby said characteristic is satisfied. A further aspect is a process to prepare a flame-retardant polyurethane comprising reacting a polyahl with an organic isocyanate in the presence of said phosphorate. An additional aspect is flame-retardant polyurethanes having said phosphorate incorporated therewith. An integral aspect is a method for inducing scorch (discoloration) in a polyurethane comprising subjecting a curing polyurethane to a substantially elevated humidity at a substantially elevated temperature.

The (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate can be simply and efficiently prepared. The use of said phosphorate can greatly improve procedures for preparing flame-retardant polyurethanes and thus may greatly improve their marketability. Significantly, for example, essentially non-scorching flame-retardant flexible polyurethane foams, especially as slabstock, can be prepared. And, flame-retardant polyurethanes which are essentially non-odoriferous can be thus prepared. The method for inducing scorch can be readily used to generally select, especially under stringent conditions, polyurethane formulations not prone to scorch under less stringent conditions such as commercial production.

ILLUSTRATIVE EMBODIMENTS

The (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is a tris(organic)phosphorate. The three organic moieties are apportioned among one haloneocarbyl-substituted and two aliphatic hydrocarbon moieties.

The haloneocarbyl moiety is a halogen-substituted hydrocarbon or oxyhydrocarbon moiety which contains a neocarbyl moiety. The neocarbyl moiety has a quaternary (i.e., 4° ) carbon. The 4° carbon is connectable to the phosphorus through aliphatic carbon to carbon or ether linkages. The neocarbyl moiety is connected to the phosphorus through an oxygen such as in a phosphate ester.

The neocarbyl moiety is more preferably a β-haloneocarbyl moiety. The β-haloneocarbyl moiety is a saturated halogen and carbon-containing moiety which has the 4° carbon bonded directly to a carbon which forms a bond connectable to the phosphorus through an oxygen such as in a phosphate ester. The β-haloneocarbyl moiety is preferably haloalkyl.

Connectable herein means directly or indirectly bonded such as by covalent bonds. Connected herein means directly bonded.

The (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is preferably a phosphate ester of the general formula ##STR1## wherein X is separately at each occurrence hydrogen, halo or C₁₋₅ (i.e., from 1 to about 5 carbons) alkyl or C₁₋₅ haloalkyl;

Q is separately at each occurrence C₂₋₁₀ (i.e., from 1 to about 10 carbons) hydrocarbyl, C₃₋₁₀ oxyhydrocarbyl (i.e., ether-substituted), C₃₋₁₀ halohydrocarbyl or C₃₋₁₀ oxyhalohydrocarbyl;

n is an integer from zero to about 5;

R is separately at each occurrence C₁₋₁₀ aliphatic hydrocarbyl; but

Q or X contains at least one halo moiety.

Preferably therein,

X is in at least one occurrence a halo moiety, and the remaining X is hydrogen, halo or C₁₋₅ haloalkyl, preferably hydro (H) or halo;

Q is C₂₋₄ alkyl or C₃₋₄ haloalkyl;

n is from zero to 2, preferably zero; and

R is separately at each occurrence C₂₋₅ alkyl.

The halogens include fluorine (F), chlorine (Cl), bromine (Br) and iodine (I). Thus, the halo moieties include fluoro, chloro, bromo and iodo. Preferred halo moieties are chloro and bromo.

More preferred haloneocarbyl moieties include those such as ((CH₂ BR)₂ CH₂ CL)CCH₂ --OQ--_(n) ; (CH₂ Br(CH₂ Cl)CCH₂ --OQ--_(n) ; (CH₂ BR)₃ CCH₂ --OQ--_(n) ; (CH₂ Cl)₃ CCH₂ --OQ--_(n) ; ((CH₂ BR)₂ CH₂ F)CCH₂ --OQ--_(n) ; ((CH₂ BR)₂ CH₃)CCH₂ --OQ--_(n) ; (CH₂ Br(CH₂ Cl)(CH 3))CH₂ --OQ--_(n) ; ((CH₂ BR)₂ C₂ H₄ Br)CCH₂ --OQ--_(n) ; ((CH₂ Br)₂ C₂ H₄ Cl)CCH₂ --OQ--_(n) ; (CH₂ Br(CH₂ Cl)(C₂ H₄ Br))CCH₂ --OQ--_(n) ; ((CH₂ Br)₂ C₂ H₄ F)CCh₂ --OQ--_(n) ; and ((CH₂ Br)₂ C₂ H₅)CCH₂ --OQ--_(n). Most preferred haloneocarbyl moieties are those such as ((CH₂ Br)₂ CH₂ Cl)CCH₂ --OQ--_(n) ; (CH₂ Br(CH₂ Cl)₂)CCH₂ --OQ--_(n) ; (CH₂ Br)₃ CCH₂ --OQ--_(n) and (CH₂ Cl)₃ CCH₂ --OQ--_(n), especially ((CH₂ Br)₂ CH₂ Cl)CCH₂ --OQ--_(n).

More preferred Q moieties include those such as C₂ H₃ (CH₂ Cl); C₃ H₅ Cl; C₂ H₃ (CH₂ Br); C₃ H₅ Br; C₂ H₃ (CH₂ F); C₃ H₅ F; C₂ H₄ and C₂ H₃ (CH₃). Most preferred are Q moieties such as C₂ H₃ (CH₂ Cl); C₃ H₅ Cl; C₂ H₃ (CH₂ Br) and C₃ H₅ Br, especially C₂ H₃ (CH₂ Cl) or C₂ H₃ (CH₂ Br) in combination with C₃ H₅ Cl or C₃ H₅ Br (n=2) as (C₂ H₃ (CH₂ Cl)--O--C₃ H₅ Cl); (C₂ H₃ (CH₂ Br)--O--C₃ H₅ Cl); (C₂ H₃ (CH₂ Cl)--O--C₃ H₅ Br); and (C₂ H₃ (CH₂ Br)--O--C₃ H₅ Br), particularly the Q moiety (C₂ H₃ (CH₂ Cl)--O--C₃ H₅ Cl).

However, n is more preferably zero. Thus, most especially preferred haloneocarbyl moieties include those such as 3-chloro-2,2-bis(bromomethyl)propyl; 3-bromo-2,2-bis(chloromethyl)propyl; 3-bromo-2,2-bis(bromomethyl)propyl; 3-chloro-2,2-bis(chloromethyl)propyl; 3-fluoro-2,2-bis(bromomethyl)propyl and 2,2-bis(bromomethyl)propyl, particularly the 3-chloro-2,2-bis(bromomethyl)propyl.

More preferred R moieties include C₂₋₄ alkyl, that is, ethyl; propyl and butyl. Most preferred are C₂₋₄ n-alkyl, that is, ethyl; n-propyl and n-butyl.

Thus, preferred (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorates include those such as, for example, (3-bromo-2,2-bis(methyl))bis(ethyl)phosphorate and (3-bromo-2,2-bis(bromomethyl))bis(n-butyl)phosphorate. The most preferred is (3-chloro-2,2-bis(bromomethyl))bis(ethyl)phosphorate.

The (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate can be prepared by the process to prepare said phosphorate comprising contacting a carbylphosphorate acid halide with a carbyloxide. Conditions are those sufficient to prepare said phosphorate.

The carbylphosphorate acid halide is an organic phosphorate which has either one or two of the organic ester moieties substituted with a halide, preferably separately at each occurrence selected from the group consisting of fluorido, chlorido and bromido. More preferably, the halide of the carbylphosphorate acid halide is selected from the group consisting of chlorido and bromido.

Preferably, the carbylphosphorate acid halide is of the general formula ##STR2## wherein X' is separately at each occurrence F, Cl or Br, preferably Cl or Br;

Z is appropriately selected from the haloneocarbyl moiety or the aliphatic hydrocarbyl moieties, preferably the foregoing ##STR3## or R moieties; and z is either 1 or 2.

The carbylphosphorate acid halides are also those such as can be prepared with diols and a phosphorus trihalide, followed by halogenation, such as disclosed by Birum et al., U.S. Pat. No. 3,132,169 (1964) (incorporated herein by reference). Preferable diols include those such as neopentyl glycol; dibromo neopentyl glycol; dichloro neopentyl glycol and 2-(bromomethyl)-2-ethyl-1,3-propanediol.

The carbylphosphorate acid halide can be obtained or prepared by known procedures or as disclosed herein. For example, the carbylphosphorate acid halide can be prepared by reacting a phosphorus trihalide such as, for example, phosphorus trifluoride; phosphorus trichloride; phosphorus tribromide with the appropriate monohydroxy alcohol which corresponds to the haloneocarbyl or the aliphatic hydrocarbyl moieties to be bound to the phosphorus as phosphate ester. See for example, copending U.S. patent application No. 843,452, filed Mar. 24, 1986 (incorporated herein by reference). Or, the carbylphosphorate acid halide can be prepared by halogenating the appropriate corresponding tris(organic)phosphite, most preferably a tris(lower alkyl)phosphite. This halogenation can be carried out with halogenating agents such as, for example, elemental fluorine, chlorine, bromine and iodine and bromine chloride, preferably, chlorine and bromine.

The carbyloxide is an oxygen-containing organic compound which appropriately correponds to the haloneocarbyl or the aliphatic hydrocarbyl moieties. Suitable carbyloxides include

alkali metal organic oxides, especially hydrocarbyloxides, including alkali metal alkoxides, for example, sodium butoxide;

monohydroxyl alcohols (preferably contacted with the carbylphosphorate acid halide in the presence of an acid acceptor), especially of the general formula ROH with R as defined herein;

oxetanes (preferably contacted with the carbylphosphorate acid halide in the presence of a Lewis acid catalyst) such as, for example, 3-bromoethyl-3-methyloxetane, 3-bromomethyl-3-ethyloxetane, 3,3-bis(chloromethyl)oxetane, 3-(chloromethyl)-3-methyloxetane; and

neocarbyl-containing oxiranes (also preferably contacted with the carbylphosphorate acid halide in the presence of the Lewis acid catalyst) such as of the general formula ##STR4## wherein Q and X are as defined herein; n' is an integer from zero to 4, preferably 1. The neocarbyl-containing oxiranes can be prepared by a procedure such as that disclosed by Gibbons, U.S. Pat. No. 3,784,500 (1974) (incorporated herein by reference).

In general, in preparing the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate, the carbylphosphorate acid halide to carbyloxide equivalent ratio can correspond roughly to a 1:1 equivalent ratio based on the number of equivalents of acid halide in the carbylphosphorate acid halide. For example, (3-bromo-2,2-dimethylpropyl)bromidochloridophosphorate contains two equivalents of acid halide, the acid bromide (bromido) and the acid chloride (chlorido), and thus, two equivalents of the appropriate carbyloxide, for example, sodium butoxide, are preferably employed to prepare the corresponding (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate.

Temperatures, in general, can be those employed with the preparation of other organic phosphate esters. Temperatures are preferably from about -10° C. (minus 10° C.) to about 120° C. Initial contact is preferably carried out at cooler temperatures such as about normal room temperature, for example, 25° C., or below. Extended contact time, if desired or necessary, is preferably carried out at elevated temperatures such as about 30° C. or above.

Pressures, in general, can be those employed with the preparation of other organic phosphate esters. Preferably, the pressure is ambient pressure.

Times (duration) are those which are sufficient to carry out the preparation. Typical times can be the time it takes for the initial contact to an extended time such as 100 hours or more. Preferably, the time is extended beyond the initial contact for about 1 to 20 hours.

The acid acceptor employed in conjunction with the alcohols can be a compound such as, for example, pyridine or sodium carbonate. The acid acceptor oan be added in the appropriate increments to thus accept acid produced by reaction with the carbylphosphorate acid halide.

The Lewis acid catalyst employed in conjunction with the neocarbyl-containing oxiranes and oxetanes is preferably a compound such as aluminum tribromide, aluminum trichloride or titanium tetrachloride. For the most part, the Lewis acid catalysts can be employed in amounts from about 1/10 to about 5 percent by weight based on the weight of the carbylphosphorate acid halide.

The reaction can be run neat or can employ a diluent. Preferably, a liquid diluent is employed. Preferred liquid diluents include halogenated alkanes such as, for example, methylene chloride, chloroform, carbon tetrachloride and 1,2-dichloroethane.

The (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is preferably purified by procedures generally analogous to those in the Birum patent, U.S. Pat. No. 3,132,169 (1964), for example, neutral or basic aqueous wash of the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate product. A dilute acid wash of the product can be employed, preferably with an aqueous mixture of the acid, especially with catalysts such as AlCl₃. The product mixture ratio is typically not changed by the dilute acid wash. Purification by distillation is a preferred step.

The process can prepare an extremely pure product which contains little or no undesired phosphorate by-products. Preferably, the desired (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is 90 percent free of other phosphorate by-products, or more pure, as determined by gas chromatographic methods (e.g., capillary), more preferably about 95 percent or more pure, and most preferably, 99 percent or more pure.

The (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate may be a low viscosity liquid such as by Brookfield viscosity. The Brookfield viscosity is the viscosity measured at 25° C. on a Brookfield viscometer with a number 6 spindle rotating at 100 rotations per minute (rpm) submersed with sample in the center of a sample vessel with a width at least 125 percent of the spindle diameter.

Preferably, the Brookfield viscosity of the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate product is about 10,000 centipoise (cP) or below at 25° C., more preferably about 5,000 cP or below and most preferably about 2,500 cP or below. It is especially preferred that the Brookfield viscosity of the product at 25° C. is about 1,000 cP or below.

Preferably, the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate has high thermal stability. One preferred method to measure this is by thermogravimetric analysis (i.e., TGA), where the sample tested is continuously monitored for weight loss as its temperature is progressively increased in an oven with a nitrogen atmosphere. The progressive temperature increase is at a rate of 20° C. per minute from an initial temperature of 20° C. with the sample size initially between 0.010 g and 0.020 g. Under these test conditions, thermogravimetric analyses preferably have a 50 percent weight loss of sample (TGA₅₀) at a temperature of about 200° C. or above, more preferably about 230° C. or above and most preferably about 260° C. or above.

The thermogravimetric analysis at 10 percent weight loss (TGA₁₀) can be used also. The TGA₁₀ is otherwise measured as is the TGA₅₀. Preferred TGA₁₀ values include values found at about 160° C. or above, more preferably about 200° C. or above and most preferably about 220° C. or above.

In general, the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate can be employed as a component in flame-retardant polyurethanes. Amounts thus employed are preferably those sufficient to render the polyurethane flame-retardant, such as in amounts from about 1/2to 50 percent by weight of other polyurethane components, for example, in amounts from about 5 to 20 percent by weight of polyahl of a foam. The use can typically satisfy at least one production characteristic of the polyurethanes.

The polyurethanes of this invention comprise organic polyisocyanates, polyahls and flame-retardant amounts of the phosphorate compounds of this invention. The polyahls are organic compounds with at least two active hydrogen moieties such as determined by the Zerewitnoff test (see, e.g., Kohler et al., J. Am. Chem. Soc., 49, 3181-88 (1927)) and with an average molecular weight of at least about 60 g per mole. See, for example, Rosenkranz et al., U.S. Pat. No. 3,928,299 (1975) (incorporated herein by reference) for compounds otherwise known which may thus be considered polyahls. The polyurethanes can be prepared by known methods such as disclosed by Hoppe et al., U.S. Pat. No. Re. 24,514 (reissued 1958) (incorporated herein by reference). The foams may also be prepared by the froth technique as described by Dunlap et al. in U.S. Pat. No. 3,755,212 (1973); by Barron et al. in U.S. Pat. No. 3,821,130 (1974); and by Walters et al. in U.S. Pat. No. 3,849,146 (1974) which are also incorporated herein by reference. The most preferred technique is the "one-shot" technique, where all the reactants are added simultaneously at the time of foaming, because it is generally used to prepare flexible polyurethane foams. Most, if not all, modern flexible slabstock (continuous) polyurethane foam machines are designed on the basis of this approach.

Of the polyahls, polyols are preferred. Preferred polyols include triol polyether polyols with equivalent weights from about 500 to 2,500 and blends of triols and diols with overall active hydrogen functionality of from about 21/2 to 3. See, for example, Baggett et al., U.S. Pat. No. 2,871,219 (1959); Smith, U.S. Pat. No. 2,891,073 (1959); Pannell, U.S. Pat. No. 3,058,921 (1962) (each incorporated herein by reference).

Especially preferred polyisocyanates include a mixture of 80 percent by weight 2,4-toluene diisocyanate with 20 percent by weight 2,6-toluene diisocyanate (generally known as TDI 80/20 or T-80) and a mixture of 65 percent by weight 2,4-toluene diisocyanate with 35 percent 2,6-toluene diisocyanate (TDI 65/35 or T-65). These are typically used in flexible polyurethane foams. The TDI 80/20 is more preferred.

Also preferred are pure and polymeric methylene-4,4'-diphenyldiisocyanate (MDI). The MDI is typically used in rigid polyurethane foams.

Other components can be present in the preparation of the polyurethanes, especially the foams, as is generally known in the art. For example, catalysts such as nitrogenous catalysts such as amino compounds, for example, those disclosed by McEntire, U.S. Pat. No. 4,101,470 (1978); Zimmerman et al., U.S. Pat. No. 4,433,170 (1984); Jachimowicz, U.S. Pat. No. 4,450,246 and Zimmerman et al., U.S. Pat. No. 4,464,488 (1984) (each incorporated herein by reference) can be employed with other catalysts such as tin compounds including those such as stannous chloride and tin salts of carboxylic acids such as, for example, stannous octoate and dibutyltin di-2-ethylhexanoate, as well as other organometallic compounds such as disclosed by Brachhagen et al., U.S. Pat. No. 2,846,408 (1958) (incorporated herein by reference). Also, a wetting agent or surface-active agent can be employed, especially in preparing high grade foams, preferably a silicone containing organic compound or block polyethers of propylene glycol prepared with ethylene oxide and propylene oxide. Also, a chain-extending agent, which is a compound with at least two active hydrogens per molecule such as, for example, 1,2-diaminoethane; (R)-1,2-dimethylaminopropane; 2-aminoethanol; ethylene glycol; L-alanine and preferably water can be employed. Also, especially in the preparation of the foamed polyurethanes, an auxiliary blowing agent preferably such as a volatile haloalkane, for example, trichlorofluoromethane, can be employed.

Preferred flexible polyurethane foam formulations with which the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorates are incorporated as a flame retardant include compositions such as follows:

    ______________________________________                                                           Concentration                                                Reactant          (pph)                                                        ______________________________________                                         polyol            100                                                          TDI index         80-120                                                       flame retardant   6-18                                                         water             1.0-5.5                                                      silicone surfactant                                                                              0.2-3                                                        tertiary amine catalyst                                                                          0.02-2                                                       auxiliary blowing agent                                                                          0.5-40                                                       tin catalyst      0.05-0.5                                                     ______________________________________                                    

Also, flexible foams with densities from about 1.0 pound per cubic foot (i.e., about 16 kg per m³) to about 4.0 pounds per cubic foot (i.e., about 64 kg per m³) are preferred.

The polyurethane production characteristic(s) which is (are) satisfied, or even improved, by the method of this invention, is preferably selected from the group consisting of

(1) processability;

(2) scorch;

(3) odor; and

(4) flame-retardant efficiency.

Processability is a production characteristic which can be satisfied or improved. A preferred measure of the processability is the Brookfield viscosity.

Processability difficulties for higher viscosity flame-retardant compounds may be reduced by the use of diluents such as non-halogenated phosphate ester compounds. Preferably, such diluents are not used in processing.

Scorch is a production characteristic which may be satisfied or improved by being reduced to minimal levels or even eliminated. A preferred measure of scorch (discoloration) is a ΔE in National Bureau of Standards (i.e., NBS) units by the Hunter Colorimeter test of about 10 or below, more preferably about 6 or below and most preferably about 4 or below, or, particularly in a laboratory scale test, after inducing scorch by the Wampfler-Fielding procedure described herein, comparable Hunter test ΔE values of about 20 or below; 10 or below; 8 or below.

The Hunter test differs from the known Gardner Colorimeter test in that in the Hunter test, the color of both the sample set and control set are compared to the color of a standard pure white tile. The standard white tile may contain pure white MgO. If the sample versus control difference is determined by subtraction (i.e., sample-control) after this comparison to the tile, the values of the Hunter test are typically substantially equivalent to values determined by the Gardner test. The Gardner Colorimeter test is more completely described in Albright et al., U.S. Pat. No. 4,083,825 (1978) from column 8, line 58 to column 11, line 23 (which material is incorporated herein by reference).

The most preferred polyurethane foam sample for the Hunter Colorimeter test, especially with flexible foams, is a representative sample taken from a large-scale commercial production bun. The bun is cross-sectioned and the whole large-scale cross-section of bun is tested for scorch in the minimum number of required 4.0 square-inch (26 cm²) cross-sections (2.0 inches × 2.0 inches; 5.1 cm × 5.1 cm), and each smaller-scale ΔE value is summed, and the summation is divided by the required number of 4.0 square-inch cross-sections. This is the average ΔE value of the large-scale sample. The sample is 2.0 inches (2.5 cm) in height. Thus, the sample is a cube of 2.0 inches per side.

As an indicia of scorch resistance when incorporated into a polyurethane, especially in a flexible foam, the thermal stability properties of the phosphorate flame-retardant compounds may be used.

Odor is a production characteristic which may be satisfied or improved by being reduced or even eliminated. The presence of a halogenated neopentane, for example, tetrabromoneopentene, at levels of about 1-4 percent by weight, may cause the odor. Keeping the presence of such a halogenated neopentane to levels below 1 percent by weight, more preferably 0.5 percent by weight, typically eliminates such an odor in the resulting flame-retardant polyurethane, especially in slabstock foam. The instant process, especially by the procedures which employ the bis(hydrocarbyl)phosphorate acid halides as the carbylphosphorate acid halide, typically does not produce such an odoriferous halogenated neopentane.

Flame-retardant efficiency is a production characteristic which may be satisfied or improved. By flame-retardant it is meant that the phosphorate, when incorporated into the polyurethane, reduces the propensity of the polyurethane to propagate combustion after the removal of a small-scale ignition source such as a lit Bunsen burner. The flame-retardant efficiency in additive-type flame-retardant phosphorus compounds incorporated with polyurethanes is typically a function of phosphorus-halogen content. Thus, brominated compounds are preferred. A higher bromine content increases the flame-retardant efficiency by its mere presence within the composition. Also, thus, the lower alkyl ester compounds are preferred. The C₂₋₄ alkyl esters are most preferred because the methyl ester has a tendency to hydrolyze more easily and thus cause a humid aging problem.

One preferred method to measure this flame-retardant efficiency is an oxygen index (i.e., limiting oxygen index) measured by the oxygen demand test of ANSI/ASTM D-2863-77 (ASTM American National Standard) wherein the minimum concentration of oxygen in a mixture of dry O₂ and dry N₂ flowing upward, needed to cause combustion in a standard test column that will just support combustion under equilibrium conditions of candle-like burning is measured. Other conditions of the ANSI/ASTM D-2863-77 oxygen demand test include those set out in the ASTM American National Standard test (incorporated herein by reference).

Preferably, for ten appropriate A through D type (as in the D-3863-77 standard) specimens with the flame-retardant composition, the average limiting oxygen index (i.e., average LOI) is raised 10 percent or more, more preferably 20 percent or more and most preferably 30 percent or more, when measured either by time until extinguishing of the flame or distance of the burned specimen according to ASTM D-2863-77, when compared to ten otherwise comparable specimens without the flame-retardant composition. It is also preferred that the average LOI of ten appropriate A through D type specimens is raised to above 21, more preferably to about 25 or above and most preferably, to about 30 or above.

When incorporated into a rigid polyurethane foam, such as an insulating foam, preferred measures include the Steiner tunnel test of ASTM E-84 or the equivalent such as Underwriter's Laboratories 723. It is preferred that the rigid foam pass the E-84 test or equivalent with a Class II rating or better. It may be desired to incorporate into the flame-retardant composition an amount effective to secure a Class I rating. Other tests such as the German DIN-4102-B2 test or its Swiss counterpart may be used.

When incorporated into a flexible polyurethane foam as a flame retardant, a preferred measure of the flame-retardant efficiency of the flame-retardant foam composition is the two-part California 117 test (i.e., both of the Vertical Burn tests and the Smoldering test) as in California Technical Bulletin 117, State of California Department of Consumer Affairs Bureau of Home Furnishings, North Highlands, Calif. (January, 1980) (which is incorporated herein by reference). It is preferred that the two-part California 117 test is passed by the flame-retardant flexible foam composition.

In each of the foregoing, it is preferred that the flame-retardant efficiency be substantially retained after aging. A preferred measure of this retention may be obtained by subjecting the flame-retardant polyurethane to elevated temperature (e.g., 104° C.) aging in a circulating air oven for 24 hours, followed by passing the requirements of the foregoing flame-retardant efficiency tests, such as in the case of a flexible foam by passing the California 117 Vertical Burn test.

Reduction of scorch and odor are each, and especially in combination, of high priority. Reduction of problems due to odor and processability or scorch and processability are also desirable. Reduction of each of the problems due to processability, scorch, odor and loss of flame-retardant efficiency is most desired.

Preferably, the method of employing the (haloneopentyl-substituted)bis(aliphatic hydrocarbyl)phosphorate as a flame retardant is generally akin to the method disclosed in copending U.S. patent application Ser. No. 811,086, filed Dec. 19, 1985 (incorporated herein by reference).

SPECIFIC EMBODIMENTS

The following examples further illustrate the invention. Parts and percentages are by weight unless otherwise specified.

Examples 1 through 4 further illustrate the (haloneopentyl-substituted)bis(aliphatic hydrocarbyl)phosphorates and their preparation. Examples 5 and 6 further illustrate employment of the (haloneopentyl-substituted)bis(aliphatic hydrocarbyl)phosphorates as a flame retardant with the polyurethanes.

EXAMPLE 1 Preparation of phosphoric acid: dibutyl, (3-bromo-2,2-dimethylpropyl)ester of the following general formula (Al) by the following general sequence with the alkali metal organic oxides ##STR5## A. Preparation of the carbyloxide sodium n-butoxide

Into a flask is placed 300 ml of 1-butanol (1.0 mole +). This mixture is stirred under nitrogen while 23 g of sodium is added in portions. The mixture is then stirred at reflux until the reaction is complete.

B. Preparation of the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate (Al)

The mixture is then cooled to cold water temperatures while 164 g of (3-bromo-2,2-dimethylpropyl)bromidochloridophosphorate is added dropwise. Upon completion of this addition, the mixture is refluxed for 6 hours. The solvent is distilled off, and the resulting product is taken up in a mixture of 250 ml of methylene chloride and 250 ml of water and is stirred in. The product layer is separated and is stirred with 250 ml of water, is again separated and is dried over sodium sulfate and is filtered. The solvent is distilled off under reduced pressure at 80° C. to produce the oily product (168 g) at 94 percent theoretical yield.

EXAMPLE 2 Preparation of phosphoric acid: diethyl, (3-chloro-2,2-bis(bromomethyl)propyl)ester of the following general formula (A2) by the following general sequence with the oxetanes ##STR6##

Into a flask are placed 61 g of 3,3-bis(bromomethyl)oxetane (0.25 mole), 200 ml of 1,2-dichloroethane, 44 g of bis(ethyl)chloridophosphorate and 1 ml of TiCl₄. This mixture is stirred at reflux for 12 hours and is then allowed to cool to room temperature (25° C.). Then 150 ml of dilute HCl is added, and the mixture is stirred. The product phase is separated and stirred with 150 ml of a dilute (lN) NaOH water solution. Following this, the product phase is separated and is dried over sodium sulfate and is filtered. The solvent is removed under reduced pressure to produce the oily product (95 g) at 91 percent theoretical yield with Brookfield viscosity (number 6 spindle; 100 rpm; 25° C.) of 200 cP. TGA_(1O) : 220° C.; TGA₅₀ : 260° C.

EXAMPLE 3 Preparation of phosphoric acid: diethyl, (3-bromo-2,2-bis(bromomethyl)propyl)ester of the following general formula (A3) by the following general sequence with the oxetanes ##STR7## A. Preparation of the carbyl phosphorate acid halide bis(ethyl)bromidophosphorate

Into a flask is placed 41.5 g of triethyl phosphite (0.25 mole). This is stirred with 350 ml of 1,2-dichloroethane at 10° C., and next 40 g of bromine (0.5 mole) is added dropwise. The reaction is stirred until persistant bromine color is gone.

B. Preparation of the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate (A3)

TiCl₄ (1 ml) is added and the mixture is stirred, and next 61 g of 3,3-bis(bromomethyl)oxetane (0.25 mole) is added dropwise. Upon completion of this addition, the mixture is refluxed for 8 hours and is then allowed to cool to room temperature. The product phase is washed once with 100 ml of dilute (lN) aqueous HCl, then additionally with 50 ml of the dilute HCl and then 100 ml of dilute (lN) NaOH water solution. The product layer is separated, is dried over sodium sulfate and is filtered. The low boilers are distilled off at 80° C. under reduced pressure to produce the oily product (82 g) at 71 percent theoretical yield with a Brookfield viscosity (number 6 spindle; 100 rpm; 25° C.) of 300 cP.

EXAMPLE 4 Preparation of phosphoric acid: diethyl, 2-chloro-3-(1-chloro-3-(3-bromo-2,2-bis(bromomethyl)propoxy)2-propoxy)propyl ester of the following general formula (A4) by the following general sequence with the neocarbyl-containing oxiranes ##STR8##

Into a flask are placed 29 g of bis(ethyl)chloridophosphorate (0.17 mole), 0.1 g of AlCl₁₃ and 100 ml of methylene chloride. This mixture is stirred while a solution of 79 g of 3-(3-bromo-2,2-bis(bromomethyl)propoxy)-1-chloro-2-propyl glycidyl ether (0.16 mole) in 50 ml of methylene chloride is added dropwise. Upon completion of this addition, the mixture is stirred at reflux for 8 hours and is then allowed to cool to room temperature. The product phase is next stirred with 50 ml of dilute base, is separated, dried over sodium sulfate and is filtered. The low boilers are removed at 80° C. under reduced pressure to produce the oily product (92 g) at 85 percent theoretical yield with Brookfield viscosity (number 6 spindle; 100 rpm; 25° C.) of 750 cP.

EXAMPLE 5 with Comparative Preparation, scorch inducement and evaluation of polyurethanes with the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate and comparative A. Preparation

A flexible polyurethane foam is prepared as follows. The foam has an isocyanate index of 110.

First, the A-side (isocyanate side) is weighed out into a half-cup (118 ml) glass jar and set aside. The A-side is 62.3 g of Voranate* T-80 (*Trademark of The Dow Chemical Company), a mixture of toluene-2,4- and 2,6-diisocyanates in a weight ratio of toluene-2,4-diisocyanate to toluene-2,6-diisocyanate of about 80:20.

Next, the B-side (polyahl side) is weighed out and is placed, in the numerical sequence listed, into a one-quart (946 ml) paper cup set beside the set aside A-side.

    ______________________________________                                                                 (g)                                                    B-Side Component        Weight                                                 ______________________________________                                         Voranol* 3137 (*Trademark of The Dow                                                                   100.0                                                  Chemical Co.) (a polyether polyol                                              with a hydroxyl number of about                                                53.4)                                                                          Sample FR               10.0                                                   ((haloneocarbyl-substituted)bis-                                               (aliphatic hydrocarbyl)phosphor-                                               ate separately of Examples 2 or                                                4 or Thermolin ® 101 (Olin Chemi-                                          cal Co.) (comparative))                                                        Water                   5.0                                                    Q-25125                 1.0                                                    (silicone surfactant available                                                 from The Dow Corning Corp.)                                                    Methylene chloride      6.0                                                    NIAX ™ A200 (amine catalyst                                                                         0.30                                                   available from Union Carbide)                                                  T-10 (50% solution of stannous                                                                         0.60                                                   octoate available from M&T                                                     Chemical)                                                                      ______________________________________                                    

Next, the B-side is mixed with a high speed electric drill-powered stirrer for 15 seconds. Next, the A side is immediately added, and immediately mixed with the drill-stirrer for 5 seconds.

The A-B mixture is immediately poured into an 83-ounce (2.45-liter) clean cardboard bucket, and the resultant foam is allowed to rise, the bucket being in upright position in an upright 5-gallon (18.9-liter) pail, the bucket disjointed from and above the surface of 1/2 gallon of water in the pail.

B. Scorch inducement by the Wampfler-Fielding procedure

Following "blow-off" the lid of the pail containing the water is put into place and the covered pail containing the bucket is placed in a 160° C. oven for one hour. The relative humidity in the covered pail is thus approximately 100 percent. Next, the bucket with foam is removed from the pail, and the foam is allowed to cool to room temperature at ambient conditions in the bucket.

The foregoing severe conditions are employed to attempt to induce scorch because generally humid conditions are a cause of scorch (discoloration), especially in flexible foams and particularly in those with phosphorus- or halogen-containing components. The high temperature and the time duration are employed because of their resemblance to the conditions which can accompany commercial scale production of foamed polyurethanes, especially flexible slabstock. Overall, the induced conditions are more severe than typically encountered in polyurethane foam production.

Substantially elevated (oven) temperatures such as from about 120° C. to 180° C., and times from 10 minutes to 2 or 3 hours may also be employed to thus induce polyurethane scorch. A substantially elevated humidity of about 50 percent or above may also be employed to thus induce polyurethane scorch.

C. Evaluation

A two-inch (5.08-cm) cross-sectional slice is cut off near the top of each foam sample. Next, a two-inch section is cut from the middle of each cross-sectional slice. The underside of this section is used for color determination.

Color is measured on a Macbeth Colorimeter using the Hunter Color Scale. The Hunter Color Scale compares the color of the sample to a standard white tile.

Three measurements are made for each sample and then averaged. The average delta E value (ΔE) for each sample is then compared to the average ΔE value determined by the Hunter Color Scale for an otherwise equivalent foam sample section containing no flame retardant. A value (ΔE(FOAM)) is calculated according to the following equation.

    ΔE(FOAM)=ΔE(SAMPLE)-ΔE(NO FR FOAM)

The following is obtained.

    ______________________________________                                         SAMPLE FR        ΔE                                                                              ΔE (FOAM)                                        ______________________________________                                         Example 2        13.3    6.3                                                   Example 4        17.6   10.6                                                   Thermolin ® 101                                                                             17.5   10.5                                                   None             7.0    --                                                     ______________________________________                                    

The ΔE(FOAM) values as are obtained with the SAMPLE FR of Examples 2 and 4 are comparable to or even better than the value as is obtained with the comparative SAMPLE FR. The comparative (Thermolin® 101) is typically sold as a substantially non-scorching flame retardant. Thus, the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorates are at least substantially, even essentially, non-scorching flame retardants for polyurethanes.

The foams are flame-retardant. The foam with SAMPLE FR of Example 2 passes the requirements of the California 117 test. The foams with the SAMPLE FR of Examples 2 and 4 are at least substantially non-odoriferous. The foam with SAMPLE FR of Example 4 is essentially non-odoriferous.

EXAMPLE 6 Commercial-type production

If, by the one-shot technique, a commercial-type scale slabstock flexible polyurethane foam with about 110 isocyanate index is prepared with about 10 pph of (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate incorporated therein, the foam is easily processable and is flame-retardant. In addition, the foam exhibits high flame-retardant efficiency, passing the California 117 test as set out by the California 117 test requirements, is essentially non-scorching and is essentially non-odoriferous. 

We claim:
 1. A (haloneocarbyl-substituted)-bis(aliphatic hydrocarbyl) phosphorate represented by the formula ##STR9## wherein X is separately at each occurrence hydrogen, halo or C₁₋₅ alkyl or C₁₋₅ haloalkyl;Q is separately at each occurrence C₂₋₁₀ hydrocarbyl, C₃₋₁₀ oxyhydrocarbyl C₃₋₁₀ halohydrocarbyl or C₃₋₁₀ oxyhalohydrocarbyl; n is an integer from 1 to about 5; R is separately at each occurrence C₁₋₁₀ aliphatic hydrocarbyl; provided that Q or X contains at least one halo moiety.
 2. The compound of claim 1 whereinX is in at least one occurrence a halo moiety, and the remaining X is hydrogen, halo or C₁₋₅ haloalkyl; Q is C₂₋₄ alkyl or C₃₋₄ haloalkyl; n is from one or 2; and R is separately at each occurrence C₂₋₅ alkyl.
 3. The compound of claim 2 wherein the halo moieties are selected from the group consisting of fluoro, chloro and bromo.
 4. The compound of claim 3 wherein the halo moieties are selected from the group consisting of chloro and bromo; the R is C₂₋₄ n-alkyl; the n is 1 or 2, and the remaining X is selected from the group consisting of hydro and halo.
 5. A process to prepare a (haloneopentyl-substituted)bis(aliphatic hydrocarbyl)phosphorate comprising contacting a carbylphosphorate acid halide with a carbyloxide under conditions whereby said phosphorate is prepared.
 6. A method for satisfying a production characteristic of a flame-retardant polyurethane comprising incorporating a (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate into polyurethane whereby said production characteristic is satisfied.
 7. The method of claim 6 wherein said production characteristic is selected from the group consisting of processability; scorch; odor and flame-retardant efficiency.
 8. The method of claim 7 whereby said production characteristic is improved, and the polyurethane is a flexible slabstock foam.
 9. A process to prepare a flame-retardant polyurethane comprising reacting a polyahl with an organic isocyanate in the presence of a (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate.
 10. The process of claim 9 wherein the polyurethane is a flexible foam, and the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is selected from the group consisting of (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate and (3-bromo-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate.
 11. Flame-retardant polyurethanes having a (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate of claim 1 incorporated therewith.
 12. The composition of claim 11 which is substantially non-scorching and non-odoriferous.
 13. The composition of claim 12 which is a flexible foam.
 14. The composition of claim 13 which is a slabstock flexible foam.
 15. The composition of claim 13 which passes the California 117 flame-retardant test.
 16. The composition of claim 14 which passes the California 117 flame-retardant test.
 17. The composition of claim 16 wherein the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is selected from the group consisting of (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate and (3-bromo-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate.
 18. The composition of claim 11 wherein the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate.
 19. The composition of claim 14 wherein the (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate is (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate.
 20. The composition of claim 16 wherein the (haloneocarbyl-substitited)bis(aliphatic hydrocarbyl)phosphorate is (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate.
 21. A composition of matter comprising a (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate and a polyahl.
 22. A polyahl composition comprising a polyahl and an amount of a (haloneocarbyl-substituted)bis(aliphatic hydrocarbyl)phosphorate sufficient to be a flame retardant in a polyurethane prepared by reacting the polyahl with an organic polyisocyanate.
 23. The composition of claim 22 wherein the polyahl is a polyether polyol and the phosphorate is a phosphorate represented by the formula: ##STR10## wherein X is separately at each occurrence hydrogen, halo or C₁₋₅ alkyl or C₁₋₅ haloalkyl;Q is separately at each occurrence C₂₋₁₀ hydrocarbyl, C₃₋₁₀ oxyhydrocarbyl C₃₋₁₀ halohydrocarbyl or C₃₋₁₀ oxyhalohydrocarbyl; n is an integer from 1 to about 5; R is separately at each occurrence C₁₋₁₀ aliphatic hydrocarbyl; provided that Q or X contains at least one halo moiety and the polyether polyol is a triol polyether or a blend of a triol and diol having an overall active hydrogen functionality of 2.5 to
 3. 24. The composition of claim 23 wherein the phosphorate is one according to the formula of claim 23 whereinX is in at least one occurrence a halo moiety, and the remaining X is hydrogen, halo or C₁₋₅ haloalkyl; Q is C₂₋₄ alkyl or C₃₋₄ haloalkyl; n is form zero to 2; and R is separately at each occurrence C₂₋₅ alkyl.
 25. The composition of claim 24 wherein the phosphorate is (3-chloro-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate; (3-bromo-2,2-bis(bromomethyl)propyl)bis(ethyl)phosphorate; or (2-chloro-3-(1-chloro-3-(3-bromo-2,2-bis(bromomethyl)propoxy)2-propoxy)propyl)bis(ethyl)phosphorate. 